Monomer/Diluent Recovery

ABSTRACT

The disclosure includes a polymerization process and an olefin polymerization system. A polymerization product is produced, a vapor phase is recovered from the polymerization product, the vapor phase is fractionated in a first column to yield a fraction stream, and the fraction stream is fractionated in a second column. A first stream of the second column, which comprises a diluent, can be recycled to a first polymerization reactor. A second stream of the second column, which comprises olefin monomer, diluent, and hydrogen, can be recycled to a second polymerization reactor. Comonomer may be recycled from the first column to the first polymerization reactor, the second polymerization reactor, or both.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

FIELD

This disclosure relates to the recovery of monomer and diluent in olefinpolymerization processes and systems.

BACKGROUND

Polyolefins can be prepared by polymerization of olefins in one or morereactors where feed materials such as diluent, monomer, comonomer andcatalyst are introduced. The polymerization reaction yields one or moresolid polyolefins in a polymerization product. The solid polyolefin canbe recovered, and remaining portions of the polymerization product canbe further processed, for example, according to techniques disclosed inU.S. Pat. No. 4,589,957. An ongoing need exists for alternative and/orimproved techniques for processing the remaining portions of thepolymerization product.

SUMMARY

Disclosed embodiments include a polymerization process comprisingproducing a polymerization product; recovering a vapor phase from thepolymerization product; fractionating the vapor phase in a first columnto yield a fraction stream; fractionating the fraction stream in asecond column; emitting a first stream and a second stream from thesecond column, wherein the first stream comprises a diluent, wherein thesecond stream comprises an olefin monomer, the diluent, and hydrogen;recycling at least a portion of the diluent of the first stream to afirst polymerization reactor; and recycling at least a portion of thediluent, at least a portion of the olefin monomer, and at least aportion of the hydrogen of the second stream to a second polymerizationreactor.

Disclosed embodiments also include an olefin polymerization systemcomprising a first polymerization reactor yielding a first component ofsolid polymer of a polymerization product; a second polymerizationreactor yielding a second component of the solid polymer of thepolymerization product, wherein the second polymerization reactor is influid communication with the first polymerization reactor; at least oneseparator receiving the polymerization product from the firstpolymerization reactor, the second polymerization reactor, or both,wherein the separator yields a vapor stream; a first column receivingthe vapor stream from the separator, wherein the first column yields afraction stream; and a second column receiving the fraction stream fromthe first column, wherein the second column yields a first streamcomprising a diluent and a second stream comprising the diluent, anolefin monomer, and hydrogen; wherein at least a portion of the diluentof the first stream flows to the first polymerization reactor, whereinat least a portion of the diluent, at least a portion of the monomer,and at least a portion of the hydrogen of the second stream flows to thesecond polymerization reactor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a process flow diagram of an embodiment of an olefinpolymerization system according to the disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Disclosed herein are embodiments of olefin polymerization systems andprocesses which provide for improved diluent/monomer recovery.

FIG. 1 shows a process flow diagram of an embodiment of an olefinpolymerization system 100 according to the disclosure. The system 100may comprise a first polymerization reactor 110 which yields a firstcomponent of a solid polymer of a polymerization product; a secondpolymerization reactor 120 in fluid communication with the firstpolymerization reactor 110 and which yields a second component of thesolid polymer of the polymerization product; at least one separator 140which receives the polymerization product from the first polymerizationreactor 110, from the second polymerization reactor 120, or both; afirst column 150 in fluid communication with the at least one separator140; and a second column 160 in fluid communication with the firstcolumn 150.

The separator 140 may yield a vapor stream 142 comprising a vapor phaseand a product stream 144 comprising solid polymer. Solid polymer may berecovered from product stream 144 for subsequent use, processing, sale,etc. The first column 150 may receive the vapor stream 142 comprisingthe vapor phase from the separator 140. The first column 150 may yield afraction stream 152, a side-draw stream 154, a bottoms stream 156, orcombinations thereof. One or more components of the bottoms stream 156may flow outside system 100 for subsequent processing, use, sale, orcombinations thereof. At least a portion of the side-draw stream 154comprising olefin comonomer may flow to the first polymerization reactor110, to the second polymerization reactor 120, or both. The secondcolumn 160 may receive the fraction stream 152 from the first column150. The second column 160 may yield an overhead stream 162, a firststream 166 comprising a diluent, and a second stream 164 comprising thediluent, an olefin monomer, and hydrogen. At least a portion of thediluent of the first stream 166 may flow to the first polymerizationreactor 110. At least a portion of the diluent, at least a portion ofthe olefin monomer, and at least a portion of the hydrogen of the secondstream 164 may flow to the second polymerization reactor 120.

The system 100 may additionally comprise any equipment associated withpolymerization processes, such as but not limited to, one or more pumps,one or more control devices (e.g., a PID controller), one or moremeasurement instruments (e.g., thermocouples, transducers, and flowmeters), alternative inlet and/or outlet lines, one or more valves, oneor more reboilers, one or more condensers, one or more accumulators, oneor more tanks, one or more filters, one or more compressors, one or moredryers, or combinations thereof.

Components of the system 100 are described in more detail below.

The first polymerization reactor 110 may be in fluid communication withthe second polymerization reactor 120 via stream 114. Stream 114 (e.g.,an effluent stream) may receive the polymerization product from thefirst polymerization reactor 110. Stream 130 (e.g., an effluent stream)may receive the polymerization product from the second polymerizationreactor 120. The polymerization product may be withdrawn from the secondpolymerization reactor 120 and may flow through stream 130 to theseparator 140. Stream 130, as discussed in more detail herein, maycomprise various equipment (e.g., a continuous take-off valve, aflashline heater, etc.).

In one or more of the embodiments disclosed herein, the firstpolymerization reactor 110, the second polymerization reactor 120, orboth, may comprise any vessel suitably configured to provide anenvironment for a chemical reaction (e.g., a contact zone) for monomers(e.g., ethylene) and/or polymers (e.g., an “active” or growing polymerchain), and optionally comonomers (e.g., 1-butene, 1-hexene, 1-octene,or combinations thereof) and/or copolymers, in the presence of acatalyst to yield a polymer (e.g., a polyethylene polymer) and/orcopolymer.

The embodiment in FIG. 1 shows the first polymerization reactor 110 maybe upstream of the second polymerization reactor 120. In alternativeembodiments, the first polymerization reactor 110 may be downstream ofthe second polymerization reactor 120.

The polymerization processes performed in the reactor(s) disclosedherein (e.g., first polymerization reactor 110 and/or secondpolymerization reactor 120) may include batch or continuous processes.Continuous processes can use intermittent or continuous productdischarge. Processes may also include partial or full direct recycle ofunreacted monomer, unreacted comonomer, and/or diluent. Generally,continuous processes may comprise the continuous introduction ofpolymerization components into the first polymerization reactor 110, thesecond polymerization reactor 120, or both, and the continuous removalor withdrawal of a polymerization product from the first polymerizationreactor 110 (e.g., via stream 114), the second polymerization reactor120 (e.g., via stream 130), or both.

In embodiments, the system 100 may further comprise one or more motivedevices, such as a pump, to circulate a polymerization medium (e.g., apolymerization product slurry) in the first polymerization reactor 110,the second polymerization reactor 120, or both. An example of a pump isan in-line axial flow pump with a pump impeller disposed within theinterior of the first polymerization reactor 110 and/or an in-line axialflow pump with a pump impeller disposed within the interior of thesecond polymerization reactor 120. The impeller may, during operation,create a turbulent mixing zone within the polymerization medium (e.g., aslurry) circulating through the polymerization reactor such thatsufficient contact between different polymerization components withinthe medium may occur. For example, the impeller may assist in propellingthe a polymerization product medium through a closed loop of the firstpolymerization reactor 110 and/or second polymerization reactor 120 atsufficient speed to keep solid particulates, such as the catalyst orsolid polymer, suspended within the reactor slurry. The impeller may bedriven by a motor or other motive force.

In embodiments, the first polymerization reactor 110, the secondpolymerization reactor 120, or both may comprise a least one loop slurrypolymerization reactor. In a loop slurry polymerization reactor, olefinmonomers, and optionally olefin comonomers, may polymerize in thepresence of a diluent and catalyst to make a polymerization productslurry comprising a solid phase and a liquid phase, wherein the solidphase comprises an olefin polymer (e.g., homopolymer or copolymer asdescribed herein) having a density and/or molecular weight as disclosedherein. A loop slurry polymerization reactor may comprise vertical orhorizontal pipes interconnected by smooth bends or elbows, whichtogether form a loop. Portions of the first polymerization reactor 110,second polymerization reactor 120, or both, such as pipes thereof, mayhave cooling jackets placed therearound to remove excess heat generatedby the exothermic polymerization reactions. A cooling fluid may becirculated through jackets, for example. Examples of loop slurrypolymerization reactors and processes are disclosed in U.S. Pat. Nos.3,248,179, 4,501,885, 5,565,175, 5,575,979, 6,239,235, 6,262,191, and6,833,415, each of which is incorporated by reference in its entiretyherein.

In embodiments, first polymerization reactor 110 and/or polymerizationreactor 120 in system 100 may comprise a gas-phase reactor. Gas-phasereactors may comprise fluidized bed reactors or staged horizontalreactors. Gas-phase reactors may employ a continuous recycle streamcontaining one or more monomers continuously cycled through a fluidizedcatalyst bed under polymerization conditions. A recycle stream may bewithdrawn from the fluidized bed and recycled back into the reactor.Simultaneously, polymerization product may be withdrawn from the reactorand fresh and/or recycled monomer may be added to replace thepolymerized monomer. Likewise, copolymer product may optionally bewithdrawn from the reactor and fresh and/or recycled comonomer may beadded to replace polymerized comonomer. The reaction medium withdrawnfrom the gas-phase reactor may comprise a solid phase comprising thepolymerization product and a gas-phase comprising monomer, optionallycomonomer, and inert carrier gas(es). Examples of gas phase reactors andprocesses are disclosed in U.S. Pat. Nos. 5,352,749, 4,588,790 and5,436,304, each of which is incorporated by reference in its entiretyherein.

In embodiments the first polymerization reactor 110, the secondpolymerization reactor 120, or both may comprise a high pressurereactor. High pressure reactors may comprise autoclave or tubularreactors. Tubular reactors may have several zones where fresh monomer(optionally, comonomer), initiators, or catalysts may be added. Monomer(optionally, comonomer) may be entrained in an inert gaseous stream andintroduced at one zone of the reactor. Initiators, catalysts, and/orcatalyst components may be entrained in a gaseous stream and introducedat another zone of the reactor. The gas streams may be intermixed forpolymerization. Heat and pressure may be employed appropriately toobtain optimal polymerization reaction conditions.

In embodiments, the first polymerization reactor 110, secondpolymerization reactor 120, or both may comprise a solutionpolymerization reactor wherein the monomer (optionally, comonomer) maybe contacted with a catalyst composition by suitable stirring or othermeans. A carrier comprising an inert organic diluent or excess monomer(optionally, comonomer) may be employed. If desired, the monomer and/oroptional comonomer may be brought in the vapor phase into contact withthe catalytic reaction product, in the presence or absence of liquidmaterial. The polymerization zone is maintained at temperatures andpressures that will result in the formation of a solution of the polymerin a reaction medium. Agitation may be employed to obtain bettertemperature control and to maintain uniform polymerization mixturesthroughout the polymerization zone. Adequate means are utilized fordissipating the exothermic heat of polymerization. The reaction mediumwithdrawn from the solution polymerization reactor may comprise thepolymerization product comprising a solid phase, a liquid phasecomprising monomer (optionally, comonomer) and/or diluent, a gas phasecomprising monomer (optionally, comonomer) and/or diluent, orcombinations thereof.

Although the embodiment illustrated in FIG. 1 shows a single reactor forfirst polymerization reactor 110, the first polymerization reactor 110may comprise any suitable number and/or type of reactors. Likewise,although the embodiment of FIG. 1 shows a single reactor for secondpolymerization reactor 120, the second polymerization reactor 120 maycomprise any suitable number and/or type of reactors.

In embodiments of the disclosed system 100, production of thepolymerization product may occur in at least two stages (e.g., in atleast the first polymerization reactor 110 and the second polymerizationreactor 120). For example, the first polymerization reactor 110 mayyield a first component of the solid polymer in the polymerizationproduct resulting from a first set of polymerization conditions in thefirst polymerization reactor 110, and the second polymerization reactor120 may yield a second component of the solid polymer in thepolymerization product resulting from a second set of polymerizationconditions in the second polymerization reactor 120. The first set ofpolymerization conditions may be the same, similar to, or different thanthe second set of polymerization conditions. In embodiments, the firstpolymerization reactor 110 may comprise one or more catalysts to yieldthe first component of the solid polymer in the polymerization product,and the second polymerization reactor 120 may comprise one or morecatalysts to yield the second component of the solid polymer in thepolymerization product, wherein the one or more catalysts of the firstpolymerization reactor 110 may be the same or different from the one ormore catalysts of the second polymerization reactor 120.

In embodiments, polymerization in multiple reactors may include thetransfer of polymerization product (e.g., manually or via stream 114)from one polymerization reactor to a subsequent reactor for continuedpolymerization (e.g., as a polymerization product slurry, as a mixture,as solid polymer, or combinations thereof). Multiple reactor systems mayinclude any combination including, but not limited to, multiple loopreactors, a combination of loop and gas reactors, multiple high pressurereactors or a combination of high pressure with loop and/or gasreactors. The multiple reactors may be operated in series, in parallel,or combinations thereof.

In embodiments, the first component of the solid polymer of thepolymerization product may have a molecular weight greater than amolecular weight of the second component of the solid polymer of thepolymerization product. Additionally or alternatively, the firstcomponent of the solid polymer of the polymerization product may have adensity less than a density of the second component of the solid polymerof the polymerization product. In embodiments, the first component is alinear low density polyethylene (LLDPE). In embodiments, the secondcomponent is a high density polyethylene (HDPE).

In an embodiment, the first component may have a density about equal toor less than 0.927 g/cm³. In additional or alternative embodiments, thesecond component may have a density about equal to or greater than 0.960g/cm³.

In an embodiment, the first component may have an HLMI about equal to orless than 0.3. In additional or alternative embodiments, the secondcomponent may have an HLMI about equal to or greater than about 10.

In embodiments, the solid polymer may comprise a polyethylenehomopolymer and/or a copolymer (e.g., polyethylene copolymer). Forexample, the solid polymer may comprise a polyethylene homopolymer orcopolymer in stream 114 (after the first component of the solid polymeris formed in the first polymerization reactor 110 and before the secondcomponent of the solid polymer is formed in the second polymerizationreactor 120), and the solid polymer may comprise a polyethylenehomopolymer or copolymer in stream 130 (after the second component ofthe solid polymer is formed in the second polymerization reactor 120).

In embodiments, the solid polymer in the polymerization product maycomprise a multimodal polyethylene. The term “multimodal” means herein,unless otherwise stated, multimodality with respect to molecular weightdistribution and includes therefore a bimodal polymer. In embodiments, apolyethylene comprising at least two components, which have beenproduced according to the disclosure result in different molecularweights (e.g., a first component which has a different molecular weightthan a second component) and molecular weight distributions for thecomponents of the solid polymer (e.g., the first component and thesecond component), is referred to as “multimodal.” The prefix “multi”relates to the number of different polymer components present in thesolid polymer. Thus, for example, multimodal polymer includes so called“bimodal” polymer consisting of two components.

Conditions of a polymerization reactor, e.g., first polymerizationreactor 110, second polymerization reactor 120, or both, may be chosenand controlled for polymerization efficiency and to provide resinproperties include temperature, pressure, catalyst selection, and theconcentrations of various reactants.

Polymerization temperature can affect catalyst productivity, polymermolecular weight and molecular weight distribution. Suitablepolymerization temperature may be any temperature below thede-polymerization temperature according to the Gibbs Free energyequation. Typically this includes from about 60° C. to about 280° C.,for example, and from about 70° C. to about 110° C., depending upon thetype of polymerization and/or reactor.

Suitable pressures will also vary according to the reactor and/orpolymerization type. The pressure for liquid phase polymerizations in aloop reactor such as loop slurry polymerization reactor 110 is typicallyless than 1,000 psig, for example, about 650 psig. Pressure for gasphase polymerization is usually at about 100 to 500 psig. High pressurepolymerization in tubular or autoclave reactors is generally run atabout 20,000 to 75,000 psig.

Polymerization reactors can also be operated in a supercritical regionoccurring at generally higher temperatures and pressures. Operationabove the critical point of a pressure/temperature diagram(supercritical phase) may offer advantages.

In an embodiment, polymerization may occur in an environment having asuitable combination of temperature and pressure. For example,polymerization may occur at a pressure in a range of about 400 psi toabout 1,000 psi; alternatively, about 550 psi to about 650 psi,alternatively, about 600 psi to about 625 psi; in combination with atemperature in a range of about 130° F. to about 150° F., alternatively,from about 120° F. to about 196° F.

Polymerization reaction components of the reactor(s) disclosed herein(e.g., first polymerization reactor 110, second polymerization reactor120, or both) may include an olefin monomer, an olefin comonomer, adiluent, a molecular weight control agent, a catalyst, a co-catalyst,other co-reactants or additives known to those skilled in the art withthe aid of this disclosure, or combinations thereof. The concentrationof various reaction components can be controlled to produce a solidpolymer in the polymerization product with certain physical andmechanical properties. Additionally, the concentration of variousreaction components can be used to control ethylene efficiency.

In embodiments, a monomer may comprise an olefin. In additional oralternative embodiments, a monomer may comprise an alpha olefin.Suitable olefins include, but are not limited to, ethylene andpropylene.

In embodiments, a comonomer may comprise an unsaturated olefin having 3to 12 carbon atoms. For example, suitable comonomers may include, butare not limited to, propylene, 1-butene, 1-hexene, 1-octene, orcombinations thereof.

In embodiments, a diluent may comprise unsaturated hydrocarbons having 3to 12 carbon atoms. In embodiments, suitable diluents may include, butare not limited to, the monomer being polymerized (examples describedabove), the comonomer being polymerized (examples described above),hydrocarbons that are liquids under reaction conditions, or combinationsthereof. Further examples of suitable diluents include, but are notlimited to, propane, cyclohexane, isobutane, n-butane, n-pentane,isopentane, neopentane, n-hexane, or combinations thereof. Some looppolymerization reactions can occur under bulk conditions where nodiluent is used. An example is polymerization of propylene monomer asdisclosed in U.S. Pat. No. 5,455,314, which is incorporated by referenceherein in its entirety.

In embodiments, a suitable catalyst system for polymerizing the monomersand any comonomers may include, but is not limited to a catalyst(s) and,optionally, a co-catalyst(s) and/or a promoter(s). Nonlimiting examplesof suitable catalyst systems include Ziegler Natta catalysts, Zieglercatalysts, chromium catalysts, chromium oxide catalysts, chromocenecatalysts, metallocene catalysts, nickel catalysts, or combinationsthereof. Nonlimiting examples of co-catalyst include triethylboron,methylaluminoxane, alkyls such as triethylaluminum, or combinationsthereof. Suitable activator-supports may comprise solid super acidcompounds. Catalyst systems suitable for use in this disclosure havebeen described, for example, in U.S. Pat. No. 7,619,047 and U.S. PatentApplication Publication Nos. 2007/0197374, 2009/0004417, 2010/0029872,2006/0094590, and 2010/0041842, each of which is incorporated byreference herein in its entirety.

In embodiments, a molecular weight control agent may comprise hydrogen,cocatalyst, modifiers, other polymerization reaction componentsrecognized by one skilled in the art with the aid of this disclosure, orcombinations thereof.

In an embodiment of the system 100 and process disclosed herein, theolefin monomer may comprise ethylene, the olefin comonomer may comprise1-hexene, the diluent may comprise isobutane, the solid polymer in thepolymerization product may comprise a multimodal polyethylene, the oneor more catalysts of the reactors 110 and/or 120 may comprisemetallocene, dual metallocene, Ziegler Natta, chromium-based catalyst,or combinations thereof.

The concentrations and/or partial pressures of monomer, comonomer,hydrogen, co-catalyst, modifiers, and electron donors are important inproducing these resin properties. In embodiments, comonomer may be usedto control a density of the at least one component of the solid polymerin the polymerization product; hydrogen may be used to control themolecular weight of the at least one component of the solid polymer inthe polymerization product; cocatalysts can be used to alkylate,scavenge poisons and control molecular weight of the at least onecomponent of the solid polymer in the polymerization product;activator-support can be used to activate and support the catalyst;modifiers can be used to control product properties of the at least onecomponent of the solid polymer in the polymerization product; electrondonors can be used to affect stereoregularity, the molecular weightdistribution, or molecular weight of the at least one component of thesolid polymer in the polymerization product; or combinations thereof. Inadditional or alternative embodiments, the concentration of poisons maybe minimized because poisons impact the reactions and productproperties.

In embodiments, the concentration of inert materials in the secondpolymerization reactor 120 may comprise up to about 2% by weight of thepolymerization medium.

The polymerization reaction components may be introduced to an interiorof the first polymerization reactor 110, the second polymerizationreactor 120, or both, via inlets or conduits at specified locations(e.g., feed stream 112, feed stream 122, or both). The reactioncomponents identified above (and others known to those skilled in theart with the aid of this disclosure) may form a suspension, i.e., areactor slurry, that circulates through the first polymerization reactor110, the second polymerization reactor 120, or both.

The polymerization product may be withdrawn from the one or morepolymerization reactors present in system 100. Generally, thepolymerization product may be transferred through the stream 114 (e.g.,an effluent stream of the first polymerization reactor 110 or the secondpolymerization reactor 120) from one reactor to another (e.g., fromfirst polymerization reactor 110 to second polymerization reactor 120when first polymerization reactor 110 is upstream of the secondpolymerization reactor 120; from second polymerization reactor 120 tothe first polymerization reactor 110 when the second polymerizationreactor 120 is upstream of the first polymerization reactor 110). Thepolymerization product may be withdrawn from the downstream reactor(e.g., first polymerization reactor 110 or second polymerization reactor120) via stream 130 and conveyed via stream 130 to the separator 140. Instream 130, the polymerization product may be conveyed via a drop inpressure. In embodiments, a portion, substantially all (e.g., 85, 86,87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.9, 99.99%), orall (e.g., 100%) of liquid phase components present in thepolymerization product are converted to gas phase components.

In embodiments, stream 130 of the system 100 may comprise a continuoustake-off valve (hereinafter “CTO valve”). Additionally or alternatively,stream 130 may comprise a flashline heater. Examples of CTO valves andflashline heaters suitable for use in the disclosed system 100 aredisclosed in U.S. Patent Application Publication No. 2013/0005929, U.S.patent application Ser. No. 13/664,944, and U.S. patent application Ser.No. 13/886,893, each of which is incorporated herein by reference in itsentirety.

In embodiments, the polymerization product may comprise one or more ofsolid polymer, hydrogen, nitrogen, methane, ethylene, ethane, propylene,propane, butane, isobutane, pentane, hexane, 1-hexene, octane, 1-octene,and heavier hydrocarbons.

In embodiments, the polymerization product conveyed through stream 130may be in the form of a slurry, a mixture, or a gas phase productmixture. The form of the polymerization product (e.g., slurry, mixture,or gas phase product mixture) may be a function of the conditions (e.g.,temperature and/or pressure present at a given location in the stream130, reactor type, catalyst selection, a drop in pressure associatedwith a CTO valve in the stream 130, a heat zone associated with aflashline heater in the stream 130, or combinations thereof) in thesystem 100. For example, in stream 130, a slurry (e.g., having a liquidand solid phase) may convert to a mixture (e.g., having a solid, liquid,and vapor phase) which may then convert to the gas phase product mixture(e.g., having a solid and vapor phase). Alternatively, in stream 130, aslurry may convert directly to a gas phase product mixture.Alternatively, stream 130 may not comprise a slurry, and a mixture mayconvert to a gas phase product mixture, or stream 130 may only comprisea gas phase product mixture (e.g., when second polymerization reactor120 comprises a gas phase reactor).

In an embodiment, the slurry may comprise solid polymer and liquid phasediluent and/or monomer/comonomer (e.g., unreacted). In an embodiment,the mixture may comprise a three-phase mixture comprising liquid and/orgaseous (e.g., vaporized) diluent, liquid and/or gaseous (e.g.,vaporized) monomer/comonomer (e.g., unreacted), and solid polymer. Inembodiments, the gas phase product mixture may comprise a solid polymer,gaseous (e.g., vaporized) diluent, and gaseous (e.g., vaporized)monomer/comonomer (e.g., unreacted).

In embodiments, the solid phase may comprise various solids,semi-solids, or combinations thereof. In an embodiment, the solid phasemay comprise the solid polymer, a catalyst, a co-catalyst, orcombinations thereof.

In embodiments, the liquid phase may comprise a diluent (e.g., unreacteddiluent), monomer (e.g., unreacted monomer), comonomer (e.g., unreactedcomonomer), or combinations thereof. In embodiments, the liquid phasemay comprise ethylene in a range of from about 0.1% to about 15%,alternatively, from about 1.5% to about 5%, alternatively, about 2% toabout 4% by total weight of the liquid phase of the polymerizationproduct. Ethane may be present in a range of from about 0.001% to about4%, alternatively, from about 0.2% to about 0.5% by total weight of thepolymerization product. Isobutane may be present in a range from about80% to about 98%, alternatively, from about 92% to about 96%,alternatively, about 95% by total weight of the polymerization product.

In embodiments, the vapor phase of the polymerization product maycomprise the vaporized portion of the liquid phase. In embodiments, thevapor phase may comprise a diluent vapor (e.g., unreacted diluentvapor), monomer vapor (e.g., unreacted monomer vapor), comonomer vapor(e.g., unreacted comonomer vapor), or combinations thereof.

As used herein, an “unreacted monomer,” for example, ethylene, refers toa monomer that was introduced into a polymerization reactor during apolymerization reaction but was not incorporated into a polymer. Inembodiments, the unreacted monomer may comprise ethylene, propylene,1-butene, 1-hexene, 1-octene, a heavier hydrocarbon having adouble-bonded carbon in the first position, or combinations thereof.

As used herein, an “unreacted comonomer,” refers to a comonomer that wasintroduced into a polymerization reactor during a polymerizationreaction but was not incorporated into a polymer. In embodiments, theunreacted comonomer may comprise propylene, 1-butene, 1-hexene,1-octene, a heavier hydrocarbon having a double-bonded carbon in thefirst position, or combinations thereof.

In embodiments, a drop(s) in pressure of stream 130 may provide means ofconveyance of the polymerization product between the polymerizationreactors 110 and 120 and the separator 140.

In an embodiment, polymerization product in stream 130 may be heated tovaporize the liquid phase of the polymerization product duringconveyance therethrough. For example, a flashline heater may heat thepolymerization product conveyed through the stream 130 to vaporize atleast a portion of the liquid phase of the polymerization product.

In embodiments, the drop(s) in pressure of the stream 130 may vaporizethe liquid phase conveyed through the stream 130. In embodiments, thedrop in pressure of the may vaporize a substantial amount (e.g., atleast about 50%, 75%, 90%, 95%, 99%, 99.5%, 99.9%, 99.99%, 99.999%, or100% by weight of component) of the liquid phase in the polymerizationproduct (e.g., polymerization product slurry or mixture) prior todelivery to the separator 140. In an embodiment, the drop in pressure ofstream 130 (e.g., associated with a CTO valve and/or flashline heater),a heating of stream 130 (e.g., heating of a portion(s) a flashlineheater), or combinations thereof may vaporize at least about 50%, 75%,90%, 95%, 99%, 99.5%, 99.9%, 99.99%, 99.999%, or 100% by weight of acomponent of the liquid phase, where the component is the diluent. Inadditional or alternative embodiment, the drop in pressure of stream 130(e.g., associated with a CTO valve and/or flashline heater), the heatingof the stream 130 (e.g., heating of a portion(s) of a flashline heater),or combinations thereof may vaporize at least about 50%, 75%, 90%, 95%,99%, 99.5%, 99.9%, 99.99%, 99.999%, or 100% by weight of a component ofthe liquid phase, where the component is the comonomer (e.g.,unreacted). In additional or alternative embodiment, the drop inpressure of the stream 130 (e.g., associated with the CTO valve and/orflashline heater), the heating of the stream 130 (e.g., heating of aportion(s) the flashline heater), or combinations thereof may vaporizeat least about 50%, 75%, 90%, 95%, 99%, 99.5%, 99.9%, 99.99%, 99.999%,or 100% by weight of a component of the liquid phase, where thecomponent is the monomer (e.g., unreacted). In additional or alternativeembodiment, the drop in pressure of the stream 130 (e.g., associatedwith the CTO valve and/or the flashline heater), the heating of thestream 130 (e.g., heating of a portion(s) the flashline heater), orcombinations thereof may vaporize at least about 50%, 75%, 90%, 95%,99%, 99.5%, 99.9%, 99.99%, 99.999%, or 100% by weight of component ofthe liquid phase, where the component is hydrogen.

The separator 140 may recover solid polymer which is received fromstream 130. In one or more of the embodiments disclosed herein, thepolymerization product flowing from stream 130 (for example, a mixtureof solid polymer and at least a portion, substantially all or all of theother components, e.g., diluent and/or unreacted monomer/comonomer, arein a gas phase) may be separated into solid polymer in product stream144 and a vapor phase comprising one or more gases in stream 142 by theseparator 140.

Any suitable technique may be used to separate the polymerizationproduct to recover solid polymer. Suitable separation techniques includedistilling, vaporizing, flashing, filtering, membrane screening,absorbing, adsorbing, cycloning, gravity settling, or combinationsthereof, the polymerization product received in separator 140 from thestream 130.

The separator 140 may comprise a separation vessel capable of separatingvapor, liquid, solid, or combinations thereof. Suitable embodiments of aseparator may include a distillation column, a flash tank, a filter, amembrane, a reactor, an absorbent, an adsorbent, a molecular sieve, acyclone, or combinations thereof. In an embodiment, the separatorcomprises a flash tank. Such a flash tank may comprise a vesselconfigured to vaporize and/or remove low vapor pressure components froma high temperature and/or high pressure fluid.

In an embodiment, the separator 140 may be configured such thatpolymerization product from stream 130 may be separated into solidpolymer in product stream 144 substantially or completely free of anyliquid phase components, and into a vapor phase comprising one or moregases in vapor stream 142.

In an embodiment, the separator 140 may be configured such thatpolymerization product from stream 130 may be separated into solid phaseand liquid (e.g., a condensate) phase components in product stream 144and a gas (e.g., vapor) phase components in vapor stream 142.

The solid phase may comprise solid polymer (e.g., polyethylene,optionally, a polyethylene copolymer).

The liquid phase or condensate may comprise any liquid phase componentssuch as diluent and/or unreacted monomer/comonomer. In some embodiments,product stream 144 may comprise a concentrated slurry of the solid phaseand liquid phase in comparison to the stream 130.

The gas or vapor phase of stream 142 may comprise vaporized solvents,diluent, unreacted monomers and/or optional unreacted comonomers, wastegases (e.g., secondary reaction products, such as contaminants and thelike), or combinations thereof. In one or more embodiments, the vaporphase in vapor stream 142 may comprise hydrogen, nitrogen, methane,ethylene, ethane, propylene, propane, butane, 1-butene, isobutane,pentane, hexane, 1-hexene, heavier hydrocarbons, or combinationsthereof. In an embodiment, ethylene may be present in a range of fromabout 0.1% to about 15%, alternatively, from about 1.5% to about 5%,alternatively, about 2% to about 4% by total weight of the stream.Ethane may be present in a range of from about 0.001% to about 4%,alternatively, from about 0.2% to about 0.5% by total weight of thestream. Isobutane may be present in a range from about 80% to about 98%,alternatively, from about 92% to about 96%, alternatively, about 95% bytotal weight of the stream.

The separator 140 may be configured such that the polymerization productflowing in the stream 130 is flashed by heat, pressure reduction, orcombinations thereof such that the enthalpy of the line is increased.This may be accomplished via a heater (e.g., a flashline heater). Forexample, a flashline heater comprising a double pipe may exchange heatby hot water or steam may be utilized.

In an embodiment, the separator 140 may operate at a pressure of fromabout 50 psig to about 500 psig; alternatively, from about 130 psig toabout 190 psig; alternatively, at about 150 psig; alternatively, atabout 135 psig.

The separator 140 may additionally comprise any equipment associatedwith the separator 140, such as control devices (e.g., a PID controller)and measurement instruments (e.g., thermocouples), and level control andmeasurement devices.

In an embodiment, the horizontal distance between the separator 140 andthe polymerization reactors 110 and/or 120 may be adjusted to optimizelayout and cost. In an embodiment, the separator 140 which may be fromabout 0 to about 3,000 horizontal feet from the polymerization reactors110 and/or 120; alternatively, the separator 140 may be from about 0 toabout 1,500 horizontal feet from the polymerization reactors 110 and/or120; alternatively, the separator 140 may be from about 100 to about1,500 horizontal feet from the polymerization reactors 110 and/or 120;alternatively, the separator 140 may be from about 100 to about 500horizontal feet from the polymerization reactors 110 and/or 120;alternatively, the separator 140 may be from about 100 to about 500horizontal feet from the polymerization reactors 110 and/or 120. Invarious embodiments, the polymerization product may travel a lineardistance through stream 130 in x, y, and z coordinates, for examplethrough circuitous pipe routing, that is greater than the horizontaldistance, the vertical spacing/distance, or combinations thereof.

In the first column 150, the vapor phase fed to the first column 150 viavapor stream 142, and optionally, any comonomer fed to the first column150 via fresh comonomer stream 170 and/or any diluent fed to the firstcolumn 150 via fresh diluent stream 172, may be fractionated to yield afraction stream 152 (e.g., depicted as an overhead stream of firstcolumn 150 in FIG. 1), a heavies stream (e.g., depicted as bottomsstream 156 in FIG. 1), and a comonomer stream (e.g., depicted as aside-draw stream 154 in FIG. 1).

The vapor phase in vapor stream 142 may be subject to compression (e.g.,via a compressor) to an elevated pressure prior to introduction into thefirst column 150 such that the vapor stream 142 may comprise a gasphase, a liquid phase, or both. Vapor stream 142 may feed to a bottom,intermediate, or top portion of the first column 150.

In embodiments, the first column 150 may comprise a heavies column. Thefirst column 150 (e.g., heavies column) may operate at conditions suchthat heavy components (e.g., components heavier than C₆═) are removedfrom the first column 150 via bottoms stream 156, olefin comonomer(e.g., C₆═) is removed from the first column 150 via side-draw stream154, and light components (e.g., components lighter than C₆═) areremoved from the first column 150 in the fraction stream 152. The lightcomponents in fraction stream 152 may include vaporized solvents,diluent, unreacted olefin monomer and/or optional unreacted olefincomonomer, waste gases (e.g., secondary reaction products, such ascontaminants and the like), hydrogen, oxygen, nitrogen, methane,ethylene, ethane, propylene, propane, butane, 1-butene, isobutane,pentane, other light components known in the art with the aid of thisdisclosure, or combinations thereof. The heavy components may flow viastream 156 for further processing and/or use. Although not illustratedin FIG. 1, a portion of the bottoms stream 156 may be reboiled in a heatexchanger and returned to the bottom portion of the first column 150. Inan alternative embodiment, the olefin comonomer may be removed from thefirst column 150 via bottoms stream 156. In an embodiment, the fractionstream 152 may include a compressor through which the light componentsflow, wherein the compressor may operate at a compression ratio of lessthan 3:1, for example, 2:1. Alternatively, the fraction stream 152 maynot comprise a compressor.

In embodiments, the first column 150 may operate at a pressure of about100 psig to about 250 psig. In an embodiment, operating within thedisclosed pressure range may allow for operation of the first column 150without a compressor in the fraction stream 152. In embodiments, thefirst column 150 may operate at an overhead temperature of about 100° F.to about 200° F. and at a bottoms temperature of about 300° F. to about400° F.

In embodiments, fresh comonomer stream 170 may feed directly to thefirst column 150, indirectly to the first column 150 (e.g., via vaporstream 142), or both. The fresh comonomer stream 170 may comprise olefincomonomer, and optionally, at least one light component. The lightcomponent may comprise oxygen, nitrogen, air, methane, ethane, propane,or combinations thereof. The first column 150 may be configured toseparate the comonomer from one or more other components fed to thefirst column 150 (e.g., one or more of the light components, freshdiluent, components of vapor stream 142, etc.). For example, the olefincomonomer may flow from the first column 150 via side-draw stream 154,heavy components may flow from the first column 150 via bottoms stream156, and one or more light components including diluent and olefinmonomer may flow from the first column 150 via fraction stream 152.

In embodiments, fresh diluent stream 172 may feed directly to the firstcolumn 150, indirectly to the first column 150 (e.g., via vapor stream142), or both. The fresh diluent stream 152 may comprise diluent, andoptionally, at least one light component. The light component maycomprise oxygen, nitrogen, air, methane, ethane, propane, orcombinations thereof. The first column 150 may be configured to separatethe diluent from one or more other components fed to the first column150 (e.g., one or more light components, fresh comonomer, components ofvapor stream 142, etc.). For example, the diluent may flow from thefirst column 150 with one or more other light components via fractionstream 152, olefin comonomer may flow from the first column 150 viaside-draw stream 154, and heavy components may flow from the firstcolumn 150 via bottoms stream 156.

In embodiments, the first column 150 may comprise a vessel havinginternal components such as distillation trays (e.g., sieve-type,dual-flow, bubble cap, donut), packing materials, or both. In anembodiment, the first column 150 comprises a distillation column.

In the second column 160, the components of the fraction stream 152 maybe fractionated. In embodiments, the second column 160 may receive thefraction stream 152 (e.g., comprising C₅ and lighter components) fromthe first column 150 (e.g., the first column 150 and second column 160may be connected in series). The fraction stream 152 may pass throughvarious operating equipment such as a valve, a condenser, a cooler, anaccumulator, a compressor, instrumentation known in the art with the aidof this disclosure, or combinations thereof before feeding to the secondcolumn 160. In an embodiment, the components of the fraction stream 152may be compressed to a 2:1 ratio before entering the second column 160;alternatively, no compression of components is needed in fraction stream152. In embodiments, the components of the fraction stream 152 maycomprise a liquid phase, a gas phase, or both.

In embodiments, the second column 160 may comprise a lights column. Thesecond column 160 may operate at conditions such that a first stream 166(e.g., a bottoms stream) comprising substantially olefin-free diluentflows from the second column 160, a second stream 164 (e.g., a side-drawstream) comprising diluent, hydrogen, and olefin monomer (e.g.,ethylene, propylene, or both) flows from the second column 160, and anoverhead stream 162 comprising light components (e.g., oxygen, nitrogen,methane, ethane, propane, butane, pentane, waste gases, other componentsknown in the art with the aid of this disclosure, or combinationsthereof) flows from the second column 160. In embodiments, the overheadstream 162 may pass through various operating equipment such as a valve,a condenser, a cooler, an accumulator, a compressor, instrumentationknown in the art with the aid of this disclosure, or combinationsthereof. Although not illustrated in FIG. 1, a portion of the firststream 166 may be reboiled in a heat exchanger and returned to thebottom portion of the second column 160.

In embodiments, “substantially olefin-free” means less than about 10, 9,8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1,0.09, 0.08, 0.07, 0.06, 0.05, 0.04, 0.03, 0.02, 0.01 wt % olefin byweight of the first stream 166.

In embodiments, a concentration of hydrogen in the second stream 164 isat least 1 ppm. In additional or alternative embodiments, aconcentration of hydrogen in the second stream 164 is from about 40 ppmto about 50 ppm. In additional or alternative embodiments, theconcentration of hydrogen in the second stream 164 is less than 1 wt %by weight of the second stream 164. In additional or alternativeembodiments, the second stream 164 may comprise greater than about 5, 6,7, 8, 9, 10, or more wt % monomer (e.g., olefin monomer) by weight ofthe second stream 164. In additional or alternative embodiments, thesecond stream 164 may comprise greater than about 5 wt % monomer (e.g.,olefin monomer) by weight of the second stream 164. In additional oralternative embodiments, the second stream 164 may comprise greater thanabout 10 wt % monomer (e.g., olefin monomer) by weight of the secondstream 164.

In embodiments, the second column 160 may operate at a pressure of about150 psig to about 350 psig. In embodiments, the second column 160 mayoperate at an overhead temperature of about −20° F. to about 105° F. andat a bottoms temperature of about 66° F. to about 250° F.;alternatively, the second column 160 may operate at an overheadtemperature of about −10° F. to about 100° F. and at a bottomstemperature of about 66° F. to about 250° F.

In embodiments, the second column 160 may be configured to separate thediluent from the at least one light component. For example, the diluentmay flow from the second column 160 via first stream 166, second stream164, or both, and the at least one light component may flow from thesecond column 160 via overhead stream 162, second stream 164, or both.

In embodiments, the second column 160 may comprise a vessel havinginternal components such as distillation trays (e.g., sieve-type,dual-flow, bubble cap, donut), packing materials, or both. In anembodiment, the second column 160 comprises a distillation column.

In embodiments, the comonomer stream (e.g., side-draw stream 154)emitting from the first column 150 may recycle olefin comonomer to thefirst polymerization reactor 110, to the second polymerization reactor120, or both (as depicted in FIG. 1). In embodiments where the comonomerstream is recycled to the first polymerization reactor 110 and/or secondpolymerization reactor 120, the comonomer stream may comprise one ormore equipment comprising olefin comonomer recycle tanks operablyconnected with one or more of a comonomer recycle pump, a heatexchanger, a compressor, an accumulator, a valve, variousinstrumentation known in the art with the aid of this disclosure, orcombinations thereof. The comonomer recycle tank(s) may collectcomonomer flowing from the first column 150 for recycle to the firstpolymerization reactor 110 and/or second polymerization reactor 120. Theone or more comonomer recycle pumps may manifold with each of thecomonomer recycle tanks such that each pump may recycle comonomer fromone or a combination of the tanks to the first polymerization reactor110, the second polymerization reactor 120, or both.

In embodiments of the system 100 such as that shown in FIG. 1, the firststream 166 may recycle substantially olefin-free diluent to the firstpolymerization reactor 110, e.g., the reactor where the component of thesolid polymer having a higher molecular weight and/or lower density isformed. In embodiments where the first stream 166 is recycled to thefirst polymerization reactor 110, the first stream 166 may comprise oneor more equipment comprising diluent recycle tanks operably connectedwith one or more of a diluent recycle pump, a heat exchanger, a treater(e.g., an isobutane treater), a compressor, an accumulator, a valve,various instrumentation known in the art with the aid of thisdisclosure, or combinations thereof. The diluent recycle tank(s) maycollect diluent flowing from the second column 160 for recycle to thefirst polymerization reactor 110 via first stream 166. The one or morediluent recycle pumps may manifold with each of the diluent recycletanks such that each pump may recycle diluent from one or a combinationof the tanks to the first polymerization reactor 110.

In embodiments of the system 100 such as that shown in FIG. 1, thesecond stream 164 may recycle monomer (e.g., olefin monomer), hydrogen,and diluent to the second polymerization reactor 120, e.g., the reactorwhere the component of the solid polymer having a lower molecular weightand/or higher density is formed. In embodiments where the second stream164 is recycled to the second polymerization reactor 120, the secondstream 164 may comprise equipment comprising recycle tanks operablyconnected with one or more of a recycle pump, a heat exchanger, atreater (e.g., an isobutane treater), a compressor, an accumulator, avalve, various instrumentation known in the art with the aid of thisdisclosure, or combinations thereof. The recycle tank(s) of secondstream 164 may receive components comprising olefin monomer, hydrogen,and diluent flowing from the second column 160 for recycle to the secondpolymerization reactor 120 via second stream 164. The one or more pumpsmay manifold with each of the recycle tanks such that each pump mayrecycle the second stream 164 from one or a combination of the tanks tothe second polymerization reactor 120.

Disclosed herein are embodiments of a polymerization process which maycomprise producing a polymerization product (e.g., in firstpolymerization reactor 110, second polymerization reactor 120, or both);recovering a vapor phase from the polymerization product; fractionatingthe vapor phase in a first column 150 (e.g., to yield a fraction stream152); fractionating the fraction stream in a second column 160; emittinga first stream 166 and a second stream 164 from the second column 160,wherein the first stream 166 comprises a diluent, wherein the secondstream 164 comprises an olefin monomer, the diluent, and hydrogen;recycling at least a portion of the diluent of the first stream 166 to afirst polymerization reactor 110; and recycling at least a portion ofthe diluent, at least a portion of the olefin monomer, and at least aportion of the hydrogen of the second stream 164 to a secondpolymerization reactor 120. The polymerization process may furthercomprise feeding fresh comonomer to the first column 150 (e.g., directlyor indirectly as described herein), feeding fresh diluent to the firstcolumn 150 (e.g., directly or indirectly as described herein), or both.The process may further comprise fractionating the vapor phase in thefirst column 150 to yield a comonomer stream comprising olefincomonomer, and recycling at least a portion of the olefin comonomer inthe comonomer stream to the first polymerization reactor 110, to thesecond polymerization reactor 120, or both.

The step of producing a polymerization product may comprise polymerizingthe olefin monomer, and optionally an olefin comonomer, in the presenceof the diluent to yield a first component of a solid polymer in thepolymerization product in the first polymerization reactor; andpolymerizing the olefin monomer, and optionally the olefin comonomer, inthe presence of the diluent to yield a second component of the solidpolymer of the polymerization product in the second polymerizationreactor.

In embodiments of the process, the first component of the solid polymerof the polymerization product may have a molecular weight greater than amolecular weight of the second component of the solid polymer of thepolymerization product. In additional or alternative embodiments of theprocess, the first component of the solid polymer of the polymerizationproduct may have a density less than a density of the second componentof the solid polymer of the polymerization product.

In embodiments of the process, the olefin monomer may comprise ethylene,the olefin comonomer may comprise 1-hexene, the diluent may compriseisobutane, the solid polymer may comprise a multimodal polyethylene, oneor more catalysts of the first polymerization reactor 110 and/or secondpolymerization reactor 120 may comprise metallocene, dual metallocene,Ziegler Natta, chromium-based catalyst, or combinations thereof.

In embodiments of the process, the first stream 166 of the second column160 may comprise a bottoms stream of the second column 160. Inadditional or alternative embodiments, the second stream 164 of thesecond column 160 may comprise a side-draw stream of the second column160. In additional or alternative embodiments, the comonomer stream ofthe first column 150 may comprise a side-draw stream 154.

In embodiments, the disclosed process may comprise various additional oralternative steps consistent with the disclosure of the system 100 andprocess herein.

One or more of the disclosed embodiments improves the monomer efficiency(e.g., ethylene), diluent efficiency (e.g., isobutane), hydrogenefficiency, or combinations thereof over existing polymerizationsystems. Additionally, one or more of the disclosed embodiments mayreduce or eliminate the need for a monomer (e.g., ethylene) recoveryunit in the polymerization system 100, for example, because ethylene isrecovered in second stream 164 of the second column 160 in an amountsuitable for recycle to a polymerization reactor (e.g., firstpolymerization reactor 110). Additionally, one or more of the disclosedembodiments may reduce or eliminate the need for separate olefin-freesystems, for example, because a substantially olefin-free diluent isrecovered in the first stream 166 of the second column 160 which issuitable for recycle to a polymerization reactor (e.g., secondpolymerization reactor 120). Additionally, one or more of the disclosedembodiments may reduce or eliminate the need for compression ofcomponents in the fraction stream 152 (e.g., compression to a ratio ofonly 2:1 or no compression at all). Additionally, one or more of thedisclosed embodiments allows for the presence of greater than 1 ppmhydrogen in the second stream 164 of the second column 160 (i.e., theneed to strip hydrogen from the second stream 164 is eliminated).Additionally, the concentration of inert materials in the secondpolymerization reactor 120 may improve ethylene efficiency, i.e., reducelosses of ethylene.

ADDITIONAL DESCRIPTION

Embodiments of a system and process have been described. The followingare a first set of nonlimiting, specific embodiments in accordance withthe present disclosure:

Embodiment 1 is a polymerization process comprising producing apolymerization product; recovering a vapor phase from the polymerizationproduct; fractionating the vapor phase in a first column to yield afraction stream; fractionating the fraction stream in a second column;emitting a first stream and a second stream from the second column,wherein the first stream comprises a diluent, wherein the second streamcomprises an olefin monomer, the diluent, and hydrogen; recycling atleast a portion of the diluent of the first stream to a firstpolymerization reactor; and recycling at least a portion of the diluent,at least a portion of the olefin monomer, and at least a portion of thehydrogen of the second stream to a second polymerization reactor.

Embodiment 2 is the process of embodiment 1, wherein producing apolymerization product comprises:

polymerizing the olefin monomer, and optionally an olefin comonomer, inthe presence of the diluent to yield a first component of a solidpolymer of the polymerization product in a first polymerization reactor;and polymerizing the olefin monomer, and optionally the olefincomonomer, in the presence of the diluent to yield a second component ofthe solid polymer of the polymerization product in a secondpolymerization reactor.

Embodiment 3 is the process of embodiment 2, wherein the first componentof the solid polymer of the polymerization product has a molecularweight greater than a molecular weight of the second component of thesolid polymer of the polymerization product.

Embodiment 4 is the process of any of embodiments 2 to 3, wherein thefirst component of the solid polymer of the polymerization product has adensity less than a density of the second component of the solid polymerof the polymerization product.

Embodiment 5 is the process of any of embodiments 2 to 5, wherein theolefin monomer comprises ethylene, wherein the olefin comonomercomprises 1-hexene, wherein the diluent comprises isobutane, wherein thesolid polymer comprises a multimodal polyethylene.

Embodiment 6 is the process of any of embodiments 1 to 5, wherein thefirst stream comprises a bottoms stream of the second column, whereinthe second stream comprises a side-draw stream of the second column.

Embodiment 7 is the process of any of embodiments 1 to 6, wherein aconcentration of hydrogen in the second stream is at least 1 ppm.

Embodiment 8 is the process of any of embodiments 1 to 7, wherein theconcentration of hydrogen in the second stream is less than about 1 wt %by weight of the second stream.

Embodiment 9 is the process of any of embodiments 1 to 8, furthercomprising feeding fresh olefin comonomer to the first column.

Embodiment 10 is the process of any of embodiments 1 to 9, furthercomprising feeding fresh diluent to the first column.

Embodiment 11 is the process of any of embodiments 1 to 10, wherein thesecond stream comprises greater than about 5 wt % monomer by weight ofthe second stream.

Embodiment 12 is the process of any of embodiments 1 to 11, wherein thesecond stream comprises greater than about 10 wt % monomer by weight ofthe second stream.

Embodiment 13 is the process of any of embodiments 1 to 12, wherein thefirst stream is substantially olefin-free.

Embodiment 14 is the process of any of embodiments 1 to 13, wherein thefirst column operates at a pressure ranging from about 100 psig to about250 psig, wherein the fraction stream does not comprise a compressor.

Embodiment 15 is the process of any of embodiments 1 to 14, furthercomprising:

fractionating the vapor phase in the first column to yield a comonomerstream comprising olefin comonomer; and

recycling at least a portion of the olefin comonomer of the comonomerstream to the first polymerization reactor, to the second polymerizationreactor, or both.

Embodiment 16 is the process of embodiment 15, wherein the comonomerstream is a side-draw stream of the first column.

Embodiment 17 is an olefin polymerization system comprising:

a first polymerization reactor yielding a first component of solidpolymer of a polymerization product;

a second polymerization reactor yielding a second component of the solidpolymer of the polymerization product, wherein the second polymerizationreactor is in fluid communication with the first polymerization reactor;

at least one separator receiving the polymerization product from thefirst polymerization reactor, the second polymerization reactor, orboth, wherein the separator yields a vapor stream;

a first column receiving the vapor stream from the separator, whereinthe first column yields a fraction stream; and

a second column receiving the fraction stream from the first column,wherein the second column yields a first stream comprising a diluent anda second stream comprising the diluent, an olefin monomer, and hydrogen;

wherein at least a portion of the diluent of the first stream flows tothe first polymerization reactor,

wherein at least a portion of the diluent, at least a portion of themonomer, and at least a portion of the hydrogen of the second streamflows to the second polymerization reactor.

Embodiment 18 is the system of embodiment 17, wherein the first columnyields a comonomer stream comprising olefin comonomer, wherein at leasta portion of the olefin comonomer of the comonomer stream flows to thefirst polymerization reactor, to the second polymerization reactor, orboth.

Embodiment 19 is the system of embodiment 18, wherein comonomer streamis a side-draw stream of the first column.

Embodiment 20 is the system of any of embodiments 17 to 19, wherein thefirst component of the solid polymer of the polymerization product has amolecular weight greater than a molecular weight of the second componentof the solid polymer of the polymerization product.

Embodiment 21 is the system of any of embodiments 17 to 20, wherein thefirst component of the solid polymer of the polymerization product has adensity less than a density of the second component of the solid polymerof the polymerization product.

Embodiment 22 is the system of any of embodiments 17 to 21, wherein aconcentration of hydrogen in the second stream is at least 1 ppm.

Embodiment 23 is the system of any of embodiments 17 to 22, wherein theconcentration of hydrogen in the second stream is less than 1 wt % byweight of the second stream.

Embodiment 24 is the system of any of embodiments 17 to 23, wherein thefirst stream is substantially olefin-free.

Embodiment 25 is the system of any of embodiments 17 to 24, furthercomprising a fresh comonomer stream fed to the first column.

Embodiment 26 is the system of embodiment 25, wherein the freshcomonomer stream comprises comonomer and at least one light component,wherein the first column separates the comonomer of the fresh comonomerstream from the at least one light component.

Embodiment 27 is the system of any of embodiments 17 to 26, furthercomprising a fresh diluent stream fed to the first column.

Embodiment 28 is the system of embodiment 27, wherein the fresh diluentstream comprises diluent and at least one light component, wherein thesecond column separates the diluent of the fresh diluent stream from theat least one light component.

Embodiment 29 is the system of any of embodiments 17 to 28, wherein thesecond stream comprises greater than about 5 wt % monomer by weight ofthe second stream.

Embodiment 30 is the process of any of embodiment 17 to 29, wherein thesecond stream comprises greater than about 10 wt % monomer by weight ofthe second stream.

Embodiment 31 is the system of any of embodiments 17 to 30, wherein thefirst stream comprises a bottoms stream of the second column, whereinthe second stream comprises a side-draw stream of the second column.

Embodiment 32 is the system of any of embodiments 17 to 31, wherein thefirst polymerization reactor comprises a loop slurry polymerizationreactor, wherein the second polymerization reactor comprises a loopslurry polymerization reactor.

Embodiment 33 is the system of any of embodiments 17 to 32, wherein theolefin monomer comprises ethylene, wherein the diluent comprisesisobutane, wherein the polymerization product comprises a multimodalpolyethylene.

Embodiment 34 is the system of any of embodiments 17 to 33, wherein thefirst polymerization reactor is upstream of the second polymerizationreactor.

Embodiment 35 is the system of any of embodiments 17 to 34, wherein thefirst polymerization reactor is downstream of the second polymerizationreactor.

Embodiment 36 is the system of any of embodiments 17 to 35, wherein thefirst column operates at a pressure ranging from about 100 psig to about250 psig, wherein the fraction stream does not comprise a compressor.

While preferred embodiments of the invention have been shown anddescribed, modifications thereof can be made by one skilled in the artwithout departing from the spirit and teachings of the invention. Theembodiments described herein are exemplary only, and are not intended tobe limiting. Many variations and modifications of the inventiondisclosed herein are possible and are within the scope of the invention.Where numerical ranges or limitations are expressly stated, such expressranges or limitations should be understood to include iterative rangesor limitations of like magnitude falling within the expressly statedranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4,etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). Use of theterm “optionally” with respect to any element of a claim is intended tomean that the subject element is required, or alternatively, is notrequired. Both alternatives are intended to be within the scope of theclaim. Use of broader terms such as comprises, includes, having, etc.should be understood to provide support for narrower terms such asconsisting of, consisting essentially of, comprised substantially of,etc.

Accordingly, the scope of protection is not limited by the descriptionset out above but is only limited by the claims which follow, that scopeincluding all equivalents of the subject matter of the claims. Each andevery claim is incorporated into the specification as an embodiment ofthe present invention. Thus, the claims are a further description andare an addition to the preferred embodiments of the present invention.The discussion of a reference in the disclosure is not an admission thatit is prior art to the present invention, especially any reference thatmay have a publication date after the priority date of this application.The disclosures of all patents, patent applications, and publicationscited herein are hereby incorporated by reference, to the extent thatthey provide exemplary, procedural or other details supplementary tothose set forth herein.

What is claimed is:
 1. A polymerization process comprising: producing apolymerization product; recovering a vapor phase from the polymerizationproduct; fractionating the vapor phase in a first column to yield afraction stream; fractionating the fraction stream in a second column;emitting a first stream and a second stream from the second column,wherein the first stream comprises a diluent, wherein the second streamcomprises an olefin monomer, the diluent, and hydrogen; recycling atleast a portion of the diluent of the first stream to a firstpolymerization reactor; and recycling at least a portion of the diluent,at least a portion of the olefin monomer, and at least a portion of thehydrogen of the second stream to a second polymerization reactor.
 2. Theprocess of claim 1, wherein producing a polymerization productcomprises: polymerizing the olefin monomer, and optionally an olefincomonomer, in the presence of the diluent to yield a first component ofa solid polymer of the polymerization product in a first polymerizationreactor; and polymerizing the olefin monomer, and optionally the olefincomonomer, in the presence of the diluent to yield a second component ofthe solid polymer of the polymerization product in a secondpolymerization reactor.
 3. The process of claim 2, wherein the firstcomponent of the solid polymer of the polymerization product has amolecular weight greater than a molecular weight of the second componentof the solid polymer of the polymerization product.
 4. The process ofclaim 3, wherein the first component of the solid polymer of thepolymerization product has a density less than a density of the secondcomponent of the solid polymer of the polymerization product.
 5. Theprocess of claim 2, wherein the olefin monomer comprises ethylene,wherein the olefin comonomer comprises 1-hexene, wherein the diluentcomprises isobutane, wherein the solid polymer comprises a multimodalpolyethylene.
 6. The process of claim 1, wherein the first streamcomprises a bottoms stream of the second column, wherein the secondstream comprises a side-draw stream of the second column.
 7. The processof claim 1, wherein a concentration of hydrogen in the second stream isat least 1 ppm.
 8. The process of claim 7, wherein the concentration ofhydrogen in the second stream is less than about 1 wt % by weight of thesecond stream.
 9. The process of claim 1, further comprising: feedingfresh olefin comonomer to the first column.
 10. The process of claim 1,further comprising: feeding fresh diluent to the first column.
 11. Theprocess of claim 1, wherein the second stream comprises greater thanabout 5 wt % monomer by weight of the second stream.
 12. The process ofclaim 11, wherein the second stream comprises greater than about 10 wt %monomer by weight of the second stream.
 13. The process of claim 1,wherein the first stream is substantially olefin-free.
 14. The processof claim 1, wherein the first column operates at a pressure ranging fromabout 100 psig to about 250 psig, wherein the fraction stream does notcomprise a compressor.
 15. The process of claim 1, further comprising:fractionating the vapor phase in the first column to yield a comonomerstream comprising olefin comonomer; and recycling at least a portion ofthe olefin comonomer of the comonomer stream to the first polymerizationreactor, to the second polymerization reactor, or both.
 16. The processof claim 15, wherein the comonomer stream is a side-draw stream of thefirst column.
 17. An olefin polymerization system comprising: a firstpolymerization reactor yielding a first component of solid polymer of apolymerization product; a second polymerization reactor yielding asecond component of the solid polymer of the polymerization product,wherein the second polymerization reactor is in fluid communication withthe first polymerization reactor; at least one separator receiving thepolymerization product from the first polymerization reactor, the secondpolymerization reactor, or both, wherein the separator yields a vaporstream; a first column receiving the vapor stream from the separator,wherein the first column yields a fraction stream; and a second columnreceiving the fraction stream from the first column, wherein the secondcolumn yields a first stream comprising a diluent and a second streamcomprising the diluent, an olefin monomer, and hydrogen; wherein atleast a portion of the diluent of the first stream flows to the firstpolymerization reactor, wherein at least a portion of the diluent, atleast a portion of the monomer, and at least a portion of the hydrogenof the second stream flows to the second polymerization reactor.
 18. Thesystem of claim 17, wherein the first column yields a comonomer streamcomprising olefin comonomer, wherein at least a portion of the olefincomonomer of the comonomer stream flows to the first polymerizationreactor, to the second polymerization reactor, or both.
 19. The systemof claim 18, wherein comonomer stream is a side-draw stream of the firstcolumn.
 20. The system of claim 17, wherein the first component of thesolid polymer of the polymerization product has a molecular weightgreater than a molecular weight of the second component of the solidpolymer of the polymerization product.
 21. The system of claim 20,wherein the first component of the solid polymer of the polymerizationproduct has a density less than a density of the second component of thesolid polymer of the polymerization product.
 22. The system of claim 17,wherein a concentration of hydrogen in the second stream is at least 1ppm.
 23. The system of claim 22, wherein the concentration of hydrogenin the second stream is less than 1 wt % by weight of the second stream.24. The system of claim 17, wherein the first stream is substantiallyolefin-free.
 25. The system of claim 17, further comprising: a freshcomonomer stream fed to the first column.
 26. The system of claim 25,wherein the fresh comonomer stream comprises comonomer and at least onelight component, wherein the first column separates the comonomer of thefresh comonomer stream from the at least one light component.
 27. Thesystem of claim 17, further comprising: a fresh diluent stream fed tothe first column.
 28. The system of claim 27, wherein the fresh diluentstream comprises diluent and at least one light component, wherein thesecond column separates the diluent of the fresh diluent stream from theat least one light component.
 29. The system of claim 17, wherein thesecond stream comprises greater than about 5 wt % monomer by weight ofthe second stream.
 30. The process of claim 29, wherein the secondstream comprises greater than about 10 wt % monomer by weight of thesecond stream.
 31. The system of claim 17, wherein the first streamcomprises a bottoms stream of the second column, wherein the secondstream comprises a side-draw stream of the second column.
 32. The systemof claim 17, wherein the first polymerization reactor comprises a loopslurry polymerization reactor, wherein the second polymerization reactorcomprises a loop slurry polymerization reactor.
 33. The system of claim17, wherein the olefin monomer comprises ethylene, wherein the diluentcomprises isobutane, wherein the polymerization product comprises amultimodal polyethylene.
 34. The system of claim 17, wherein the firstpolymerization reactor is upstream of the second polymerization reactor.35. The system of claim 17, wherein the first polymerization reactor isdownstream of the second polymerization reactor.
 36. The system of claim17, wherein the first column operates at a pressure ranging from about100 psig to about 250 psig, wherein the fraction stream does notcomprise a compressor.